EP2441132B1 - Elektrische konnektoren und sensoren zur verwendung in öl- und gasbohrlöchern mit hoher temperatur und hohem druck - Google Patents

Elektrische konnektoren und sensoren zur verwendung in öl- und gasbohrlöchern mit hoher temperatur und hohem druck Download PDF

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Publication number
EP2441132B1
EP2441132B1 EP10786490.2A EP10786490A EP2441132B1 EP 2441132 B1 EP2441132 B1 EP 2441132B1 EP 10786490 A EP10786490 A EP 10786490A EP 2441132 B1 EP2441132 B1 EP 2441132B1
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EP
European Patent Office
Prior art keywords
electrical connector
electrical
conductor pin
connector
thermoplastic body
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP10786490.2A
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English (en)
French (fr)
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EP2441132A4 (de
EP2441132A1 (de
Inventor
Christopher S. Ring
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kemlon Products & Development Co Ltd
RING CHRISTOPHER S
Original Assignee
Kemlon Products & Development Co Ltd
KEMLON PRODUCTS AND DEV CO Ltd
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Publication of EP2441132A1 publication Critical patent/EP2441132A1/de
Publication of EP2441132A4 publication Critical patent/EP2441132A4/de
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/533—Bases, cases made for use in extreme conditions, e.g. high temperature, radiation, vibration, corrosive environment, pressure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • H01R13/405—Securing in non-demountable manner, e.g. moulding, riveting
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5202—Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/66—Structural association with built-in electrical component
    • H01R13/665—Structural association with built-in electrical component with built-in electronic circuit
    • H01R13/6683—Structural association with built-in electrical component with built-in electronic circuit with built-in sensor

Definitions

  • the present invention relates to electrical connectors and sensors useful in many applications, but particularly intended for use in hostile environments. More specifically, the present invention relates to single and multi-pin electrical connectors and sensors for use in high-pressure, high-temperature applications which commonly occur in the oilfield, but which are also encountered in geothermal and research applications.
  • Oil wells are being drilled to deeper depths and encountering harsher conditions than in the past. Many of the electrical connectors in the oilfield are exposed to the environment of the open well bore, where at maximum depth, pressures rise to over 2040 Barg (30,000 psig), temperatures exceed 260°C (500 degrees, F), and the natural or chemically-enhanced well bore environment is extremely corrosive.
  • US Patent No. 7,364,451 to John H. Ring and Russell K. Ring discloses an electrical connector for use in very hot, high pressure wells using, in combination, glass seats, ceramic seals, a plastic body molded, for example, from aromatic polyetherketones or other thermoplastic materials and in some embodiments, includes a thermoplastic jacket made from PAEK, PEEK, PEK and PEKK, or the like.
  • US 6,506,083 discloses a metal-sealed, thermoplastic electrical feed through.
  • the electrical connectors of the present invention provides some of the high pressure, high temperature capabilities of the hybrid type of connectors, but having manufacturing costs quite similar to the all plastic versions of electrical connectors of the prior art.
  • FIG. 1 a prior art, all plastic electrical connector 10 having an electrical conductor located within the interior of an all plastic body 14, with the plastic body 14 typically molded around the metal electrical conductor 12.
  • a rubber O-ring 16 is also located on the exterior surface of the plastic body 14.
  • a threaded metal body 18 encircles a portion of the plastic body 14. All too often, the plastic body 14 extrudes away from the electrical conductor 12, allowing the conductor 12 to touch the metal body 18, causing immediate failure of the intended function of the connector 10.
  • FIG. 2 illustrates a second failure mode of the all plastic, prior art connector 10 illustrated in FIG. 1 .
  • the pin 12 When used with a rubber boot 20, the pin 12 depends upon electrical contact with electric conductor 22 in normal operation.
  • the boot normally excludes conductive fluids from reaching the conductor while making a reliable electrical connection.
  • the plastic body Under extremes of temperature and pressure, the plastic body deforms and extrudes through the threaded metal body 18, carrying with it the conductor pin 12 that disconnects with contact 22 and causing in this case both an electrical and hydraulic failure.
  • FIG.'s 3 and 4A-4F illustrate an electrical connector 30 according to the invention having a body 34 molded around the metallic electrical connector pin 32.
  • the electrical conductor pin 32 may be comprised of Inconel, Monel, copper, Alloy 52, beryllium copper, molybdenum, stainless steel, brass, nickel-iron bearing alloys, and other known conductive materials.
  • the molded plastic body 34 is preferably comprised of insulative thermoplastic, and even more preferably from aromatic polyetherketones (PEK, PEEK) but can also be comprised of other polymeric materials such as PAEK and PEKK, and blends of PEK, PEEK, PAEK and PEKK with other plastics, thermosets, modifiers, extenders and polymers.
  • PEK aromatic polyetherketones
  • the insulating bushing 36 is comprised of a strong insulator, preferably from ceramic, zirconia, or other known strong insulators, for example, aluminium oxide (Alumina), mullite, silicon nitride, or forsterite.
  • a strong insulator preferably from ceramic, zirconia, or other known strong insulators, for example, aluminium oxide (Alumina), mullite, silicon nitride, or forsterite.
  • Non-conductive silicon carbide can also be used as a strong insulator, but it should be appreciated that some versions of silicon carbide are conductive and should not be used as a strong insulator for this application.
  • the insulating bushing 36 is comprised of an electrical insulator with high compressive strength, preferably ceramic, zirconia, or similar material that will not melt, weaken or significantly degrade at well bore temperatures. The present invention does not use a glass seal.
  • the threaded support washer/sleeve 38 can be comprised from a variety of metals, but preferably is comprised of beryllium copper, Inconel or stainless steel.
  • the O-ring is comprised of rubber.
  • the threads on the washer/sleeve 38 are typically provided for installation of the connector, but are considered to be optional.
  • insulating bushing 36 of FIG. 4A , the support washer/sleeve 38 of FIG. 4B and the conductor pin 32 of FIG. 4C are preferably fabricated as single components, and then assembled, but could be fabricated, if desired, as a single component comprising the conductor pin 32, the insulating bushing 36 and the washer/sleeve 38, or as a single component combining any one of the three components with one of the remaining two components.
  • FIG. 4D illustrates, before the molding step, the assembly of components 32, 36 and 38, with the insulating bushing 36 being slidably engaged over the conductor pin 32 until preferably contacting a shoulder on the conductor pin 32.
  • the connectors according to the invention preferably has the shoulder on the conductor pin 32, but the connector according to the invention will also function in an acceptable manner without the shoulder, as illustrated and described with respect to FIG. 10 .
  • the washer/sleeve 38 is slidably engaged over the exterior surface of the insulating bushing 36 until a shoulder of the insulating bushing 36 preferably engages a shoulder of the washer/sleeve 38.
  • All three components are preferably assembled together, wherein such components are fixedly connected together by well known processes involving bonding, cement, glue, epoxy or other materials, in the final assembly, having melting temperatures well in excess of 260°C (500° F) to remain secure during molding at very high temperatures and very high pressures.
  • FIG. 4E illustrates the assembly illustrated in FIG. 4D , after the molding step, but prior to the machining step used to achieve the end product illustrated in FIG. 4F .
  • the O-ring 40 With the O-ring 40 in place, also shown in FIG. 3 and in FIG. 4E , the molded body 35 becomes body 34 as a consequence of the final machining step.
  • the electrical conductor pin or pins each have a plurality of enlarged diameter areas, for example, areas 33 in FIG. 4G .
  • the diameter of the area 33 is preferably greater than the diameter of the conductor pin 32 mounted within the interior channel of the ceramic insulating bushing 36. This difference in diameter creates a seal between the thermoplastic body 34 ( FIG.
  • the electrical conductor pins 132 may be comprised of Inconel, Monel, Alloy 52, beryllium copper, molybdenum, stainless steel, brass, nickel-iron bearing alloys, and other known conductive materials.
  • the molded plastic body 134 is preferably comprised of insulative thermoplastic, and even more preferably from aromatic polyetherketones (PEK, PEEK) but can also be comprised of other polymeric materials such as PAEK and PEKK, and blends of PEK, PEEK, PAEK and PEKK with other plastics, thermosets, modifiers, extenders and polymers.
  • PEK aromatic polyetherketones
  • the plurality of insulating bushings 136 are each comprised of a strong insulator, preferably from refractory materials, non-conducting silicon carbides, ceramic, zirconia or other high strength insulating materials that do not melt, weaken, or significantly degrade at well bore temperatures.
  • the threaded support washer/sleeve 138 can be comprised of a variety of metals, but preferably is comprised of beryllium copper, Inconel or stainless steel.
  • the O-ring 140 is comprised of rubber.
  • the threads on the support washer/sleeve 138 are provided for installation of the connector into the gland and are optional.
  • the manufacture and assembly process for the electrical conductor 100 of FIG. 5 is essentially identical to the process illustrated in FIG's 4A-4F, and may or may not have threads on the support washer/sleeve 138.
  • FIG. 6 there is illustrated a multi-pin electrical connector 200 according to the invention, having a plurality of electrical conductor pins 232 connected to a sensor element 242 embedded in the molded thermoplastic body 234.
  • the sensor element 242 is typically protected from the downhole environment by a cover 244, as desired, and may be fabricated from metal, rubber, plastic or other known materials as needed, depending upon the type of sensor element 242 being used.
  • the electrical connector portion 234 of FIG. 6 is manufactured and assembled essentially identically to the process used for the electrical connector 100 of FIG. 5 , other than for the use of the two connector pins 232 connected by the conductors 233 and 235, respectively, to the sensor element 242.
  • FIG. 7 there is illustrated a multi pin electrical connector 300, according to the invention, having a plurality of electrical conductor pins 332 connected, respectively, to a sensor element 341.
  • the sensor element 341 comprises a plurality of electrode rings 342, two of which are rings 333 and 335 which are tied electrically to the conductor pins 332, respectively.
  • the process for manufacturing and assembling the components included in the conductors illustrated in FIG's 3, 4A-4F, 5, 6 and 7, 8, 9 and 10 including the materials used to manufacture the component parts of each of such electrical conductors, are essentially identical.
  • the stabbing element 431 may preferably comprise beryllium copper, Inconel, copper or stainless steel.
  • the component parts 436, 438 and 440 correspond essentially with the corresponding component parts 34, 36, 38 and 40 of the connector 30 in FIG.3 , both as to the materials used, the assembly and the manufacturing process.
  • the electrical conductor pin 432 is preferably fabricated as a single part to include the stabbing element 431 having a larger diameter than the diameter of the pin end 432.
  • the body part 435 and the body part 434 are both molded from thermoplastic, and are separated from the stabbing element 431 so that electrical contact with the female receptacle (not illustrated) occurs when connector 400 is fully engaged in the intended apparatus.
  • FIG. 9 is a multi-pin connector 500 according to the invention which can withstand high pressure from either or both directions, i.e., from the conductor pin end 532 and/or from the conductor pin end 632.
  • the corresponding component parts 532 (conductor pin), 536 (insulating bushing), 538 (threaded washer sleeve), and 560 (outside diameter at first end of insulating busing 536) are identical to parts 632, 636, 638 and 660, respectively.
  • the thermoplastic body 534 and the O-ring 540 are common to both ends.
  • the treaded washer sleeves 538 and 630 can be threaded, or unthreaded, as desired.
  • thermoplastic body 34 in FIG. 3 the support washer/sleeve 38 in FIG. 3 and the insulating bushing 36 in FIG. 3 .
  • This seal is generally noted as the external surface 560 along the outside diameter of the insulating bushing 536 in FIG. 9 , but is preferably present in all the embodiments of the invention illustrated in FIG.'s 3, 4F, 5, 6, 7, 8, 9 and 10. Although being preferable, such seal is optional in all such embodiments.
  • FIG. 10 is an alternative embodiment according to the invention as illustrated in FIG. 3 , but which can be used to modify FIG.'s 3, 4A-4F, 4G, 5, 6, 7, 8 and 9 if desirable.
  • FIG. 3 for example, has a raised section on its conductor pin 32 having an outside diameter greater than the internal diameter of the insulating bushing 36 creating a seal as herein discussed.
  • the conductor pin32 may or may not have the raised section, but if present, the raised section of conductor pin 32 does not seal against the insulating bushing 36.
  • the embodiment of FIG. 3 is preferred over the embodiment of FIG. 10 , but the embodiment of FIG. 10 will still provide a viable connector.

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  • Connector Housings Or Holding Contact Members (AREA)

Claims (15)

  1. Elektrischer Verbinder (30, 100, 300, 400, 500) zur Verwendung in Hochtemperatur-Hochdruck-Öl- und -Gasbohrungen, umfassend:
    einen isolierenden thermoplastischen Körper (34, 134, 234, 334, 434, 534);
    einen metallischen elektrischen Leiterstift (32, 132, 232, 332, 434, 534), der teilweise im Inneren des genannten thermoplastischen Körpers eingebettet ist, wobei der genannte elektrische Leiterstift (32, 132, 232, 332, 432, 532) wenigstens einen Abschnitt mit einem vorgegebenen Außendurchmesser hat,
    dadurch gekennzeichnet, dass er ferner umfasst:
    eine Isolatorbuchse (36, 136, 236, 336, 436, 536), die ein erstes und ein zweites Ende mit einem Innenkanal zwischen dem genannten ersten und zweiten Ende hat, wobei der genannte elektrische Leiterstift (32, 132, 232, 332, 432, 532) sich wenigstens teilweise in dem genannten Kanal befindet, wobei der genannte Kanal einen Innendurchmesser hat, der kleiner als der Außendurchmesser von jedem des genannten wenigstens einen Abschnitts des genannten elektrischen Leiterstifts (32, 132, 232, 332, 432, 532) ist.
  2. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach Anspruch 1, wobei das erste Ende der genannten isolierenden Buchse (36, 136, 236, 336, 436, 536) abdichtend mit dem genannten wenigstens einem Abschnitt des genannten elektrischen Leiterstifts (32, 132, 232, 332, 432, 532) in Eingriff ist.
  3. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach Anspruch 1 oder 2, wobei die genannte isolierende Buchse (36, 136, 236, 336, 436, 536) Keramik umfasst.
  4. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der vorhergehenden Ansprüche, wobei die genannte isolierende Buchse (36, 136, 236, 336, 436, 536) Zirkondioxid umfasst.
  5. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der vorhergehenden Ansprüche, wobei die genannte isolierende Buchse (36, 136, 236, 336, 436, 536) ein Isoliermaterial mit hoher Druckfestigkeit umfasst, das bei Bohrlochtemperaturen weder schmilzt, schwächer wird noch bedeutend beeinträchtigt wird.
  6. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der vorhergehenden Ansprüche, ferner dadurch gekennzeichnet, dass er keine Glasdichtungen hat.
  7. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der vorhergehenden Ansprüche, der außerdem eine metallische Stützscheibe/Hülse (38, 138) umfasst, die an der Außenfläche der genannten Isolierbuchse (36, 136, 236, 336, 436, 536) montiert ist.
  8. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der vorhergehenden Ansprüche, wobei der genannte elektrische Verbinder wenigstens einen Sensor (242) umfasst, der mit dem genannten Leiterstift (32, 132, 232, 332, 432, 532) verbunden ist.
  9. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der vorhergehenden Ansprüche, wobei der isolierende thermoplastische Körper (34, 134, 234, 334, 434, 534) aromatische Polyetherketone umfasst.
  10. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach Anspruch 9, wobei der thermoplastische Körper (34, 134, 234, 334, 434, 534) PEK umfasst.
  11. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach Anspruch 9 oder 10, wobei der thermoplastische Körper (34, 134, 234, 334, 434, 534) PEEK umfasst.
  12. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der Ansprüche 9 bis 11, wobei der thermoplastische Körper (34, 134, 234, 334, 434, 534) PAEK umfasst.
  13. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der Ansprüche 9 bis 12, wobei der thermoplastische Körper (34, 134, 234, 334, 434, 534) PEKK umfasst.
  14. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der Ansprüche 9 bis 13, wobei der thermoplastische Körper (34, 134, 234, 334, 434, 534) Gemische aus wenigstens einem von PEK, PEEK, PAEK und PEKK mit wenigstens einem von anderen Kunststoffen, Duroplasten, Modifizierungsmitteln, Füllstoffen und Polymeren umfasst.
  15. Elektrischer Verbinder (30, 100, 200, 300, 400, 500) nach einem der vorhergehenden Ansprüche, wobei der elektrische Leiterstift (32, 132, 232, 332, 432, 532) zwei Abschnitte hat, die jeweils einen vergrößerten Außendurchmesser haben, wobei der Verbinder umfasst:
    zwei Isolierbuchsen (136, 236, 336, 436, 536), die jeweils ein erstes und ein zweites Ende haben und jeweils einen jeweiligen inneren Kanal zwischen den genannten ersten und zweiten Ende haben, wobei der genannte elektrische Leiterstift (132, 232, 332, 432, 532) sich wenigstens teilweise in jedem der jeweiligen genannten Kanäle befindet, wobei die genannten Kanäle jeweils einen Innendurchmesser haben, der kleiner als der vergrößerte Außendurchmesser der genannten zwei Abschnitte des genannten elektrischen Leiters ist.
EP10786490.2A 2009-06-10 2010-06-07 Elektrische konnektoren und sensoren zur verwendung in öl- und gasbohrlöchern mit hoher temperatur und hohem druck Active EP2441132B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12/455,946 US7901247B2 (en) 2009-06-10 2009-06-10 Electrical connectors and sensors for use in high temperature, high pressure oil and gas wells
PCT/US2010/001641 WO2010144125A1 (en) 2009-06-10 2010-06-07 Electrical connectors and sensors for use in high temperature, high pressure oil and gas wells

Publications (3)

Publication Number Publication Date
EP2441132A1 EP2441132A1 (de) 2012-04-18
EP2441132A4 EP2441132A4 (de) 2013-01-09
EP2441132B1 true EP2441132B1 (de) 2018-07-18

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EP10786490.2A Active EP2441132B1 (de) 2009-06-10 2010-06-07 Elektrische konnektoren und sensoren zur verwendung in öl- und gasbohrlöchern mit hoher temperatur und hohem druck

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US (1) US7901247B2 (de)
EP (1) EP2441132B1 (de)
WO (1) WO2010144125A1 (de)

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US7901247B2 (en) 2011-03-08
WO2010144125A1 (en) 2010-12-16
EP2441132A4 (de) 2013-01-09
EP2441132A1 (de) 2012-04-18
US20100317228A1 (en) 2010-12-16

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